Members: Sponsor: Dalton Hamilton Preston-Eastin Levi Edens - - PowerPoint PPT Presentation

Members: Sponsor:

Dalton Hamilton Preston-Eastin Levi Edens Kenneth Mui Brice Abbott

Mission Statement

 Wolf Pack Engineering strives to

provide our customer with innovative

• solutions. We take a cost effective idea
• r methodology to produce a successful

product.

Preston-Eastin

 Company began in 1972  Design and Manufacture  Based in Tulsa, Ok  Large Product Line  High Quality

• Safe
• Reliable
• Long Lasting

Problem Statement

 PA30 HD-6 Welding Positioner  Increase Profit Margin  Increasing Competition  Maintain Quality  Create Best Possible Solution

Current Product

Capacity Weight: 3000 pounds Offset of C.G. from table: 6 inches Eccentricity of C.G. from axis: 6 inches Rotation Motor: Variable speed DC, 1 horsepower Speed range: 0.1 to 2.0 rpm Tilt Motor: AC brakemotor, 3/4 horsepower Range: 135 degrees forward tilt Inherent Overhang: 6 inches Elevation Adjustment: Manual Range: 33" to 53" in 4" increments (to top of table) Table Diameter: 36 inch square, with four radial T

• slots

Bearings: Timken tapered roller bearings Ground: 600 amp spring-loaded mechanical ground Controls Pendant: Remote pendant 115V, with 30' cable Rotation speed: One-turn potentiometer Rotation mode: T wo-position selector switch, WELD/RAPID Rotation direction: Three-position selector switch Rotation control: START and STOP pushbuttons Tilt control: Three-position momentary switch,

Fall 2011

Financial Analysis Material Labor Quality

Fall 2011

 Financial Analysis  Unable T

• Find Substantial Savings

 Decided T

• Redesign Machine From The

Ground Up

Spring 2012 Design Plan

Complete Redesign Focus On Structural Components Focus On Power Transmission Focus On Labor Reduction Examine Competitors Product Integration Of Ideas

Structural Components

 Machine Time Reduction  Manufacture Simplification  Reduction Of Unnecessary Components

Design Changes-Outer Plates

 Single Sheet Design  Simplify Trunnion

Mounting

 Remove Unnecessary

Plates

 Decrease Machine

Time

Design Changes-Single Sheet

 5’x10’-3/8” Steel Sheet  Steel Arrives Pre-cut

Design Changes-Original Side Plates

 Right Side Plate  20 Machined Holes  Precision Machined

For Trunnion Box

 Left Side Plate  20 Machined Holes

Design Changes-Side Plates

 Right Side Plate  13 Burnt Holes  Notch Design  Less Machine Time  Easier Trunnion

Mounting

 Left Side Plate  4 Burnt Holes

Stress Analysis-Outer Plates

Name Type Min Max

Displacement URES: Resultant Displacement 0 mm Node: 135 0.0641343 mm Node: 16260 sideplate right-SimulationXpress Study-Displacement-Displacement

• 3000lb Load Applied
• Maximum Deformation .002

Inches

• Factor of Safety 6

Name Type Min Max

Displacement URES: Resultant Displacement 0 mm Node: 135 0.0320671 mm Node: 16260 sideplate right-SimulationXpress Study-Displacement-Displacement

• 1500lb Load Applied
• Maximum Deformation .001

Inches

• Factor of Safety 11

Design Changes-Inside Plates

 Removed Bottom

Plate

 Removed Front

Angled Plate

 Shortened Top Plate  Added New Front

Plate

Cost Savings

Part Original Cost Part New Cost Savings

Side Plate 45" X 25 7/8" X 3/8" (2) 193.29 Side Plate 44 1/2" X 26" X 3/8" (2) 141.15 52.14 Front Plate 35 1/2" X 13 1/2" X 3/8" 38.34 Front Plate 30 1/8" X 23 1/2" X 3/8" 43.18

• 4.84

Back Door 11 GA X 25" X 33 1/4"^ 18.83 Back Plate 33 7/8" X 26 3/8" x 3/8" 54.5

• 35.67

Bottom Plate 35 1/8" X 26 1/8" X 1/4" 60.56 Bottom Plate (N/A) 60.56 Top Plate 26 7/8" x 36" X 1/4" 63.86 Top Plate 13 3/16" X 30 7/8" X 3/8" 24.84 39.02 Manufacturing Time Hrs(20) 1040 Manufacturing Time Hrs(15) 780 260 Total 1,414.88 Total 1,043.67 371.21

Design Changes-Trunnion

 Machined to Large Tilt Gear  Has to be Precision

Machined for Alignment

 Bearings Mounted on to Side

Plate

Design Changes-Trunnion

 Attached to Tilt Gear  Through shaft  Shaft Mounted into

Notches Side Plates

 Shaft Analysis:  Min Displacement-0in

Max Displacement-.01in

 SF-5

Name Type Min Max Displacement URES: Resultant Displacement 0 mm Node: 1 0.345198 mm Node: 156 Rotation cold rolled-SimulationXpress Study-Displacement-Displacement

Cost Savings

Part Original Cost Part New Cost Savings

Box MC8-22.8# channel 27 1/2" (2) 100.13 Box Square tube 10" X 8" X 25" X 1"^ 180.00

• 79.87

End Plates 1" THK X 13 1/4" dia. 76.76 End Plates 9 7/16" X 7 7/16" X 1"^ 46.50 30.26 Tilt Rod 11" X 2 1/2" DIA HR1020* 24.76 Tilt Rod 34 1/8" X 2" DIA CR1020* 37.54

• 12.78

Mounting Plates 18 13/16" X 8" X 2" 56.91

• 56.91

Manufacturing Time Hrs(32) 1664 Manufacturing Time Hrs(10) 520 1144 Total 1,922.56 Total 794.04 1,128.52

Design Changes-Sandwich Table

 Original Sandwich

Table

 Full Channel Mesh

Welded Between Two 3/8” Steel Plates

Design Changes-Table

 Removed Back Plate  Removed Most C

Channel Web

Stress Analysis-Sandwich Table

 3000lbs Load Displaced

Over Face

 Max Displacement-.02in  Factor of Safety – 2.83  750lbs Load in Each

Corner

 Max Displacement-.06in  Factor of Safety – 1.24

Cost Savings

Part Original Cost Part New Cost Savings

Table 36" X 36" X 3/8" (2) 207.36 Table 36" X 36" X 3/8" 79.06 128.30 C channel 2" X 1" X 3/16" X 214 3/8" 49.31 C channel 2" X 1" X 3/16" X 93 1/4" 21.45 27.86 Table gard 3/16" X 128" X 1 3/8" 8.27 Table gard 3/16" X 128" X 1 3/8" 10.74

• 2.47

Manufacturing Time Hrs(10) 520 Manufacturing Time Hrs(5) 260 260 Total 784.94 Total 371.25 413.69

Design Changes-Power Transmission

 Power Transmission

• Tilt System

 Gear Boxes  Gears  Mounting

• Rotation System

Design Changes-Tilt System

 Replace Custom

Gear Box

 Remove

Unnecessary Gears

 Outside Mounting  Direct Drive To

Segment Gear

Design Changes- Tilt System

Design Changes-Tilt System

60:1 3.57:1

Reduction T

• rque

RPM .25 1750 3.57:1 .8925 490.19 60:1 53.55 8.169 10:1 535.5 .8190 T

• tal

Reduction 2142

Original vs. New Design Specs

Original Design

New Design

Tilt Range

0 - 135o

Tilt Range

0 - 135o

Tilt Motor

¾ HP AC Break Motor

Tilt Motor

¾ HP AC Break Motor

Inherent PSI

36000

Inherent PSI

35745

Reduction

2363

Reduction

2142

Capacity 6in off face

5627lbs

Capacity 6in

• ff face

4834lbs

Tilt Speed 135o In 11 ¼ sec [12o/sec] Tilt Speed 135o in 27 ½ sec [4.9o/sec]

Cost Savings

Part Original Cost Part New Cost Savings

In House Gear Box

• est. cost

1500 Boston 730D-60-J Gearbox 1000 500 Tilt Pinion Gear 18 teeth 6 pitch 65 16 tooth Gear 5 pitch 200

• 135

Tilt Drive Gear 64 teeth 8 pitch 65

• 65

Tilt Gearbox Gear 22 teeth 8 pitch 45

• 45

Tilt Gear 1/2 144 teeth gear 6 pitch 163 Tilt Gear 1/2 160 teeth 5 pitch 750

• 587

Flange Bearing SF 1 1/2 (2) 30

• 30

Cross Shaft 35" X 1 1/2" HR1020* 21.14

• 21.14

Manufaturing Time Hrs(30) 1560 Manufaturing Time Hrs(10) 520 1040 Total 3,449.14 Total 2,470 979.14

Rotation System

Rotation Reduction Reduction T

• rque in-lbs

RPM Dc Motor .33 1750 Pulley 1.78:1 .59 984 Boston Reducer 50:1 29.3 20 Table Gear 6.67:1 195.6 3.0 Total: 592.6

Electrical

 After examining the electrical

components we have determined that the current setup is what we found to be the most cost efficient.

 Foot pedal operation is now only a

additional option at approximately $400

Savings

Current Model New Design

Savings

Parts Cost Parts Cost Flat Steel Side Plate 45" X 25 7/8" X 3/8" (2) 193.29 Side Plate 44 1/2" X 26" X 3/8" (2) 141.15 52.14 Front Plate 35 1/2" X 13 1/2" X 3/8" 38.34 Front Plate 30 1/8" X 23 1/2" X 3/8" 43.18

• 4.84

Back Door 11 GA X 25" X 33 1/4"^ 18.83 Back Plate 33 7/8" X 26 3/8" x 3/8" 54.5

• 35.67

Bottom Plate 35 1/8" X 26 1/8" X 1/4" 60.56 Bottom Plate (N/A) 60.56 Top Plate 26 7/8" x 36" X 1/4" 63.86 Top Plate 13 3/16" X 30 7/8" X 3/8" 24.84 39.02 Base C channel C 4 X 7.25# X 52" (2) 51.13 C channel C 4 X 7.25# X 52" (2) 51.13 0.00 C channel C 4 X 7.25# X 34 3/4" (2) 34.17 C channel C 4 X 7.25# X 29 3/4" (2) 21.45 12.72 3" X 3" X 1/4" Sq. Tube 28 3/8" (4) 76.05 3" X 3" X 1/4" Sq. Tube 28 3/8" (4) 76.05 0.00

Savings

Current Model New Design Savings

Sandwich Table Table 36" X 36" X 3/8" (2) 207.36 Table 36" X 36" X 3/8" 79.06 128.30 C channel 2" X 1" X 3/16" X 214 3/8" 49.31 C channel 2" X 1" X 3/16" X 93 1/4" 21.45 27.86 Table gard 3/16" X 128" X 1 3/8" 8.27 Table gard 3/16" X 128" X 1 3/8" 10.74

• 2.47

Tilt System In House Gear Box

• est. cost

1500 Boston 730D-60-J Gearbox 1000 500 Tilt Pinion Gear 18 teeth 6 pitch 65 16 tooth Gear 6 pitch

• 135

Tilt Drive Gear 64 teeth 8 pitch 65 Tilt Gear 1/2 160 teeth 6 pitch 65 Tilt Gearbox Gear 22 teeth 8 pitch 45 45 Tilt Gear 1/2 144 teeth gear 6 pitch 325

• 587

Flange Bearing SF 1 1/2 (2) 30 30 Cross Shaft 35" X 1 1/2" HR1020* 21.14 21.14

Savings

Current Model New Design Savings

Trunion Box/Mounting Box MC8-22.8# channel 27 1/2" (2) 100.13 Box Square tube 10" X 8" X 25" X 1"^ 180

• 79.87

End Plates 1" THK X 13 1/4" dia. 76.76 End Plates 9 7/16" X 7 7/16" X 1"^ 46.5 30.26 Tilt Rod 11" X 2 1/2" DIA HR1020* 24.76 Tilt Rod 34 1/8" X 2" DIA CR1020* 37.54

• 12.78

Mounting Plates 18 13/16" X 8" X 2" 56.91

• 56.91

Materials 2948.87 Materials 2737.59 211.28 Labor 100hrs @ $52/hr 5,200 Labor 40-60hrs @ $52/hr 2,080-3,120 2,080-3,120 Misc. 2,204.33 Misc. 2,204.33

• Total

10353.20 Total 7021.92-8061.92 2,300-3,300

Conclusion

 6 Major Components Eliminated  Precision Machining was Eliminated  Reduced Manufacturing Time by ~ 50%  Reduced Ship Weight by ~ 40%

Questions??

Comparison of Table Specs

Pan 30-6 PA-30 HD6 WP-3000

Overall Dim

footprint 30" x 48 1/2" 38 3/16" X 52" 35 3/4" X 52" Feet 6 x 2 Channel 4 x 2 Channel 4 X 2 Channel* Overall Width 39 1/4" 38 43 1/4" Rotation Offset 4" 6" 6" C.G offset from table 4" 6" 6" Overall Length 58 1/4" 71 1/8" 71 1/8" Inherent Overhang 5 3/4" 6" 6" Tilt Axis Height 27 1/4" 27" 27" Load Capacity (lbs) 3000 3000 3000 Trunnion box Rectangle Tube C Channels weld together Rectangular Tube Trunnion size 8 X 10 X 22 1/2" 7 X 8 X 27 1/2" 8 X 10 X 25" Side walls 1/2" 3/8" 1/2" Machined hole on the side plates 16 40 17 Weld skip weld mostly mostly full welds mostly full welds Trunnion seems to be made standard and used for multiple assemblies

Table

Table layers 3 [plate, skirt & stiffener] 4 [2 plates, side plates, stiffeners, gear guard] 3 [Plate, skirt, & stiffener] Length of stiffeners 5.33 feet 16.27 feet 7.77 feet Stiffener size 1/2" x 3/4" 2" x 1" x 3/16" 2" x 1" x 3/16" Number of Table Stiffnrs 4 16 3 Gear guard attachment Trunnion Table Table shape Rectangular Rectangular/Round Square Table Size 30" sq. 36" sq. [Round] 36"sq. [Rectangular] 36" X 36" "T" Slot Quantity 4 4 4 ANSI Std "T" Nut Size 5/8" 3/4" 3/4" Table height adjustment No/ fixed Manual Manual Table Height 32 5/8" 33"-53" 32" - 52"

Rotation

Rotation motor size 1 HP 1 HP 1 HP Max Rot speed 1.4 RPM 2.0 RPM 2.0 RPM Min Rot speed 0.07 0.1 RPM 0.1 RPM Speed Acc. 2% 2% Rot torque 18000 18000 18000 Rotation reducer 60:1 50:1 50:1

Motors

Voltage 230/460 V 230/460 V 230/460 V Phases three phase three phase three phase Input power 60 hz 60 hz 60 hz Amp 14.8 @ 230 V 20/10 20/10 Transmition of power Tilt chain Belt Chain Rotation Belt Belt Belt Tilt motor location Outside of frame In frame Outside frame Rot motor location attached to trunnion In Frame In Frame Motor guards no no no

Tilt

Tilt Range 0-135° 0-135° 0-135° Tilt Motor 3/4 H.P. AC Break Motor 3/4 HP AC Break Motor 3/4 HP AC Break Motor Tilt Speed 135° in 36 sec [3.75°/sec] 135° in 11 1/4 sec [12°/sec] 135° in 27 ½ sec [4.9°/sec] Tilt Torque 32250 psi inherent 36000 36000 Tilt Gear Radius 16" 12.165" 16" Teeth 80 72 80 width 1.385" 1 1/2" 1.385" Pitch 5 6 5 Attach method Bolted welded/Bolted Bolted Tilt Axis turn attachment bushing Cross Shaft Bushing/Shaft Tilt Reductor 60:1 36:1 60:1

Misc.

Ship Weight 1750 lb. 2100 lb. ~1350 lb. Pendant cable length 25 30 30 Controls Speed,Rapid, FWD, Rev, Stop, Tilt Speed, Rot mode, FWD, REV, Tilt, Stop Speed, Rot mode, FWD, REV, Tilt, Stop pendant control all except for Tilt All All Optional Pedal No yes Yes Pendant material Mold Plastic Metal Metal Appearance Simple minimal Robust, Big, high safety factor Simple minimal machining Cost Efficient Bolt instead of weld Effective